Investigation of the Calculation Ploughing Force and the Effect of Friction Coefficient in Machining of Aluminum 6061-T6

Abstract

In metal cutting operations, the ploughing force, which occurs due to the effect of edge radius of the tool that is an essential factor in terms of tool wear, prediction of flow stress, chip formation mechanism, surface quality and finite element modeling of metal cutting operations. In the literature, the ploughing force was estimated based on the periodic force in steady state metal cutting operations. However, periodic force does not occur in most metal cutting operations. In this article, the ploughing force was estimated by integrating uncut chip thickness to zero value by using extrapolation method. After estimating the ploughing force by this method, the Coulomb friction coefficient can be calculated and the precision of the assumption is compared. The estimated ploughing force is more homogeneous when plotted against uncut chip thickness, and the Coulomb friction coefficient is quite accurate to friction value which found in the literature. Hereby, the assumption is acceptable to estimate the ploughing force by using extrapolation method and the calculation of the Coulomb friction is valid in metal cutting operation which periodic force does not occur.